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Alaqua 7004 Boulevard East, Suite 28A,Guttenberg, NJ USA 07093    +(00-1) 551 482 7568   
Alaqua 7004 Boulevard East, Suite 28A,Guttenberg, NJ USA 07093    +(00-1) 551 482 7568   

Application of Falling Film Evaporator in Sugar Industry

Application of Falling Film Evaporator in Sugar Industry

Date:18 May, 2021   |   No Comments   |   Posted By Team Alaquainc

ALAQUA is a company based in the United States that supplies processing equipment worldwide. We’ve been supplying food-grade, sanitary, and ASME code evaporators, crystallizers, spray dryers, solvent recovery, and distillation systems for over 25 years. In 1989, Alaqua founded and incorporated as a corporation in 1993. The evaporators include falling film evaporators, rising film evaporators, plate evaporators, and various other types of processing equipment.

Evaporative crystallizers

The liquid product normally reaches the evaporator from the top of falling film evaporators. The top head uniformly disperses the stock into the heating tubes. At boiling temperature, a thin film reaches the heating tube and flows downward, partly evaporating.  Inside the heating tubes, both the product and the vapours flow downward in a parallel flow. While, the gravity-induced downward acceleration is amplified by the co-current vapour wave. 

Application of Falling Film Evaporator:

The boiling liquid exhibits low-temperature variations with the heating media.falling film evaporators, and they have brief product touch intervals, usually measured in seconds per pass. The  evaporator’s suitability for heat-sensitive materials makes it the most commonly used evaporator type.

Falling film evaporators must be properly configured for each working condition; adequate wetting of the heating surface by liquid is critical for the plant’s trouble-free operation. Inadequate wetting of heating surfaces will result in the appearance of dry patches and scaling. in the worst-case scenario, the heating tubes will get clogged.

For uniform product wetting, design the evaporator head’s product delivery mechanism properly. Hence, the falling film evaporator swiftly transitions to cleaning or another product due to its low liquid holding capacity.

Changes in parameters such as energy source, vacuum, feed rate, concentrations, and so on have a big impact on falling film evaporators. They will deliver a reliable focused product when fitted with a well-designed automatic control system. falling film evaporators can work with minor temperature variations, they can be used in multiple effect setups or in modern plants with low energy consumption mechanical vapour compression systems.

Process of Falling Film:

In India, there are approximately 550 sugar factories in operation, with 70 backend refineries and 6 standalone refineries. Approximately 40% of sugar factories use falling film tubular evaporators with tube sizes of 35/45 mm and lengths of 8.0–12.0 m. About 300 sugar refineries and factories use different types of falling film evaporators around the world.

Isgec has advanced the concept of a falling film evaporator by incorporating a Novel juice distributor. However, we all know that the most essential component of Falling Film Evaporator is the juice dealer. A bad design can be disastrous, resulting in tube clogging due to sugar caramelization, which wastes a lot of sugar and reduces performance.

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Over decades, the beet sugar business consistently improved its energy economy, aiming to minimize steam use. However, the cane sugar business long neglected this issue. Hence, this mindset, however, is no longer valid.

Cane sugar mills cut steam use by investing in equipment and optimizing processes, closely monitoring energy consumption to enhance efficiency. Cogeneration’s global rise prompts cane sugar companies to monitor daily sugar and saved bagasse, using it as post-power generation energy.

Steam saving:

In order to generate additional revenue from cogeneration, the sugar process requires active steam saving. Plants with less than 30% steam for plantation white and around 40% for cane sugar mills operate effectively.

In the beet sugar sector, falling film evaporators have proven to be great performers. So, a well-designed cleaning procedure and proper discharge of non-condensable gases enable successful utilization in the cane sugar industry.

These evaporators need lower temperature and residence time, elevating final effects’ temperature in the evaporation plant compared to Roberts evaporators. While, cane sugar companies can optimize heating systems by using vapor from effects 3 and 4 for crystallization.

Combining falling film evaporators with an organized sugar house operation consistently achieves specific steam consumption values of 30-40% on cane.

We are an evaporators supplier for all kinds of evaporators, crystallizers, solvent recovery systems, distillation systems, spray dryers, and all other kinds of processing equipment. Contact us today for all kinds of processing equipment!!!

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